Acrylonitrile Butadiene Latex Production
Nitrile Butadiene Rubber Production Costs Report | Issue B | Q3 2024
| Report Details |
| 35 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 35 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Nitrile Latex (NBR latex) production from acrylonitrile and butadiene using a typical cold emulsion polymerization process, based on a plant constructed in the United States. In this process, acrylonitrile and butadiene are copolymerized into low solids content NBR Latex.
The report provides a comprehensive study of Nitrile Butadiene Rubber production and related Nitrile Butadiene Rubber production cost, covering three key aspects: a complete description of the Nitrile Butadiene Rubber production process examined; an in-depth analysis of the related Nitrile Butadiene Rubber plant capital cost (Capex); and an evaluation of the respective Nitrile Butadiene Rubber plant operating costs (Opex).
The Nitrile Butadiene Rubber production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Nitrile Butadiene Rubber plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Nitrile Butadiene Rubber plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises the following sections: (1) polymerization; and (2) monomers recovery.
Polymerization. Polymerization is comprised of continuously stirred jacketed tank reactors connected in series. To keep the low reaction temperature, all reactors are cooled by means of ammonia vaporization. Acrylonitrile and butadiene are mixed with emulsifier, demineralized water and other chemicals to form the emulsion that will be fed to the polymerization reactors. Downstream, a shortstop agent is mixed with the emulsion in order to stop reaction at the desired conversion, for the sake of avoiding gel formation.
Monomers recovery. The latex generated in polymerization reactors is flashed at atmospheric pressure and then under vacuum. Residual butadiene vapors are compressed and then cooled for condensation. The condensed stream is directed to a decanter for water removal. Recovered butadiene is recycled to a butadiene plant, where butenes are separated, so the recovered butadiene can be reused in the NBR Latex plant. The degassed latex is pumped and fed to a vacuum plate column, where residual acrylonitrile monomer is stripped by contacting the latex with steam entering the column bottom. Stripped acrylonitrile is recycled to polymerization. The latex is mixed with an antioxidant agent and finally blended into an homogeneous emulsion before being sent to storage facilities as the finished latex product.
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Production Process Information
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Nitrile Butadiene Rubber production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Nitrile Butadiene Rubber process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Nitrile Butadiene Rubber production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Nitrile Butadiene Rubber plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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This report presents the economics of Nitrile Rubber (NBR) production from acrylonitrile and butadiene using a typical cold emulsion polymerization process. In this process, an emulsion comprising water, acrylonitrile and butadiene is polymerized into a latex, which is then coagulated to form the NBR. The economic analysis is based on a plant constructed in the United States.
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